Manufacturing method of motor

ABSTRACT

A motor includes a rotor having a shaft disposed along a central axis extending in a vertical direction and a stator opposed to the rotor in a radial direction with a gap therebetween. The stator includes: an annular core back extending in a circumferential direction, a plurality of teeth extending from the core back in the radial direction, a plurality of coils formed of a conductive wire wound around the teeth. A manufacturing method includes, in at least one of the teeth: a step S1 of forming a first coil winding the conductive wire around the teeth, a step S2 of hooking the conductive wire of a winding end of the first coil to form a lead line; and a step S3 of winding the conductive wire which is the same as the first coil and the lead wire over the first coil to form a second coil.

RELATED APPLICATIONS

The present application is a divisional of U.S. patent application Ser. No. 15/751,490, filed on Feb. 9, 2018, which is a national stage entry according to 35 U.S.C. § 371 of PCT Application No.: PCT/JP2016/073266 filed on Aug. 8, 2016, which claims priority from Japanese Application No.: 2015-158392 filed on Aug. 10, 2015, the contents of each of the above-identified applications are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present disclosure relates to a motor, manufacturing method of motor, and stator unit.

DESCRIPTION OF THE RELATED ART

Conventionally, a coiling method of drawing two draw lines from one stator core is known (for example, JP 2002-84723 A and so on).

As a connection system to supply power to a stator, a motor including a plurality of connection systems is used. In such a motor with a stator coil of the above-mentioned method, two conductors drawn as a winding end of the stator coil may possibly be confused and connected to wrong busbars. Thus, there is a technical difficulty in properly forming a plurality of connection systems.

SUMMARY OF THE INVENTION

According to the present disclosure, a motor includes a rotor including a shaft disposed along a central axis extending in a vertical direction; and a stator opposed to the rotor in a radial direction with a gap therebetween, wherein the stator includes: an annular core back extending in a circumferential direction; a plurality of teeth extending from the core back in the radial direction; a plurality of coils formed of a conductive wire wound around the teeth, the coils forming a plurality of connection systems; and an insulator, at least part of which is positioned between the teeth and the coils, and wherein the coils include: a first coil wound around the teeth via the insulator; and a second coil wound around the teeth via the first coil and the insulator.

According to the present disclosure, a manufacturing method of a motor including: a rotor including a shaft disposed along a central axis extending in a vertical direction; a stator opposed to the rotor in a radial direction with a gap therebetween; and a plurality of busbars electrically connected to the stator, wherein the stator includes: an annular core back extending in a circumferential direction; a plurality of teeth extending from the core back in the radial direction; a plurality of coils formed of a conductive wire wound around the teeth, the coils forming a plurality of connection systems; and an insulator, at least part of which is positioned between the teeth and the coils, and wherein a first coil group including the coils, and a second coil group including the coils, the first coil group and the second coil group forming different connection systems, and wherein the busbars include a first busbar electrically connected to the first coil group, and a second busbar electrically connected to the second coil group, the method includes, in at least one of the teeth: a step S1 of forming a first coil winding the conductive wire around the teeth; a step S2 of hooking the conductive wire wound at the end of the first coil on the insulator to form a lead line; and a step S3 of winding the conductive wire which is the same as the first coil and the lead wire over the first coil to form a second coil.

According to the present disclosure, a stator unit includes a motor including a rotor with a shaft disposed along a central axis extending in a vertical direction, the stator unit comprising: a stator opposed to the rotor in a radial direction with a gap therebetween; and a plurality of busbars electrically connected to the stator, wherein the stator includes: an annular core back extending in a circumferential direction;

a plurality of teeth extending from the core back in the radial direction; a plurality of coils formed of a conductive wire wound around the teeth, the coils forming a plurality of connection systems; and an insulator, at least part of which is positioned between the teeth and the coils, and wherein the coils include: a first coil including a coil end connected to the busbar and wound around the teeth via the insulator; and a second coil including a coil end connected to the busbar and wound around the teeth via the first coil and the insulator.

The above and other elements, features, steps, characteristics and advantages of the present discloser will become more apparent from the following detailed description of the preferred embodiments with reference to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a motor of a preferred embodiment.

FIG. 2 is a perspective view of part of a stator unit of the preferred embodiment.

FIG. 3 is a perspective view of a lower side busbar assembly of the preferred embodiment.

FIG. 4 is a plan view of the lower side busbar assembly of the preferred embodiment.

FIG. 5 is a cross-sectional view of part of the stator of the preferred embodiment.

FIG. 6 is a perspective view of part of the stator of the preferred embodiment.

FIG. 7 is a perspective view of part of the stator of the preferred embodiment.

FIG. 8 is a perspective view of part of the stator of the preferred embodiment.

FIGS. 9A, 9B, and 9C show parts of a manufacturing method of a motor of the preferred embodiment.

FIGS. 10A, 10B, 10C, and 10D show parts of the manufacturing method of the motor of the preferred embodiment.

FIG. 11 is a perspective view of another example of an insulator of the preferred embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, a motor of the preferred embodiment of the present disclosure will be described with reference to accompanying drawings. In the present application, the upper side of a central axis J extending in a vertical direction in FIG. 1 will be referred to as upper side, and the lower side thereof will be referred to as lower side. Note that the vertical direction does not indicate a positional relationship and a direction when the motor is incorporated in an actual device. Furthermore, a direction parallel with the central axis J will be referred to as axis direction, and a radial direction around the central axis J will be referred to as radial direction, and a circumferential direction around the central axis J will be referred to as circumferential direction.

In the present application, a phrase such as extending in an axis direction includes a case where a structural element extends in the axis direction, and a case where a structural element extends in a direction inclined at an angle less than 45 degree with respect to the axis direction. A phrase such as extending in a radial direction includes a case where a structural element extends in the radial direction, that is, a direction orthogonal to the axis direction, and a case where a structural element extends in a direction inclined at an angle less than 45 degree with respect to the radial direction.

As shown in FIG. 1, a motor 10 is, for example, an inner rotor motor. The motor 10 includes a housing 20 which can accommodate parts, rotor 30, annular stator 40, bearing holder 50, lower bearing 60 held by the housing 20, upper bearing 61 held by the bearing holder 50, lower side busbar assembly 70, upper side busbar assembly 80, and terminals 92A and 92B.

The rotor 30 includes a shaft 31 disposed along the central axis J, first rotor core 33A, second rotor core 33B, third rotor core 33C, first magnet 34A, second magnet 34B, and third magnet 34C. The shaft 31 is supported rotatably about the central axis J by the lower bearing 60 and the upper bearing 61. The rotor 30 is rotatable with respect to the stator 40 inside the stator 40.

The first core 33A, second rotor core 33B, and third rotor core 33C are annular. The first rotor core 33A, second rotor core 33B, and third rotor core 33C are arranged in this order from the lower side to the upper side in the axis direction. The inner side surfaces of the first rotor core 33A, second rotor core 33B, and third rotor core 33C are, for example, cylindrical around the central axis J. The first rotor core 33A, second rotor core 33B, and third rotor core 33C are fixed to the shaft 31 by, for example, press fitting. Note that the first rotor core 33A, second rotor core 33B, and third rotor core 33C may be indirectly fixed to the shaft 31 with another member.

The first magnet 34A, second magnet 34B, and third magnet 34C are, for example, formed in a plate extending in the circumferential direction. The first magnet 34A is fixed to the outer side surface of the first rotor core 33A. The second magnet 34B is fixed to the outer side surface of the second rotor core 33B. The third magnet 34C is fixed to the outer side surface of the third rotor core 33C.

A plurality of first magnets 34A, second magnets 34B, and third magnets 34C are provided along the circumferential direction. Note that the first magnet 34A, second magnet 34B, and third magnet 34C may be formed as a single member. In that case, the first magnet 34A, second magnet 34B, and third magnet 34C are, for example, cylindrical.

The stator 40 is opposed to the rotor 30 in the radial direction with a gap therebetween. The stator 40 is, for example, disposed outside the rotor 30 in the radial direction. The stator 40 includes a stator core 40 a, a plurality of coils 43, and a plurality of insulators 44. The stator core 40 a is, for example, a layered structure of a plurality of electromagnetic steel sheets. The stator core 40 a includes an annular core back 41 extending in the circumferential direction and a plurality of teeth 42 extending in the radial direction from the core back 41. That is, the stator 40 includes the core back 41 and the teeth 42.

The core back 41 is, for example, a cylinder around the central axis J. The outer peripheral surface of the core back 41 is fixed to the inner peripheral surface of the housing 20 by, for example, press fitting. In the present embodiment, the teeth 42 extend inwardly in the radial direction from the inner side surface of the core back 41. The teeth 42 are arranged at regular intervals in the circumferential direction.

The coil 43 is formed of a conductive wire 43 a wound around the teeth 42 with the insulator 44 interposed therebetween. The coil 43 is arranged on each of the teeth 42. The coil 43 includes a coil end 43 b which is an end of the conductive wire 43 a. The coil end 43 b extends to the upper side from a position where the coil 43 is wound around the teeth 42. At least part of the insulator 44 is disposed between the teeth 42 and the coils 43. The insulator 44 covers at least part of the teeth 42.

The lower side busbar assembly 70 is substantially cylindrical. The lower side busbar assembly 70 is disposed above the stator 40. The lower side busbar assembly 70 includes a neutral point busbar 90 and a substantially cylindrical lower side busbar holder 71 which holds the neutral point busbar 90.

The lower side busbar holder 71 is formed of, for example, an insulative resin. The lower side busbar holder 71 is fixed to the insulator 44. The neutral point busbar 90 is electrically connected to the coil 43. Specifically, the neutral point busbar 90 is connected to the coil end 43 b. Thus, the neutral point busbar 90 is electrically connected to the stator 40. The neutral point busbar 90 connects a plurality of coil ends 43 b as a neutral point.

The upper side busbar assembly 80 is substantially cylindrical. The upper side busbar assembly 80 is disposed above the lower side busbar assembly 70. The upper side busbar assembly 80 includes a phase busbar 91 and an upper side busbar holder 81 holding the phase busbar 91. That is, the motor 10 includes the phase busbar 91 and the upper busbar holder 81.

The upper busbar holder 81 is substantially cylindrical and is formed of, for example, an insulative resin. The upper busbar holder 81 is fixed to the housing 20. The phase busbar 91 is electrically connected to the coil 43. Specifically, the phase busbar 91 is connected to the coil end 43 b. The phase busbar 91 is connected to the terminals 92A and 92B. Thus, the phase busbar 91 is electrically connected to the stator 40.

The terminals 92A and 92B are plate-like members extending to the upper side. Ends of the terminals 92A and 92B in the upper side are disposed above the end of the housing 20 in the upper side. The terminals 92A and 92B are connected to an external power source which is not shown.

As shown in FIG. 2, in the present embodiment, a stator unit 11 includes the stator 40, upper side busbar assembly 80, and lower side busbar assembly 70. The stator unit 11 includes the phase busbar 91 of the upper side busbar assembly 80 and the neutral point busbar 90 of the lower side busbar assembly 70. Hereinafter, each part of the stator unit 11 will be described.

The upper side busbar holder 81 includes a second coil support 82 of substantially cylindrical shape, outer tube 83 of cylindrical shape, first peripheral wall 84, second peripheral wall 85, third peripheral wall 86, and terminal holders 87A and 87B. The motor 10 includes an insulative second coil support 82.

The outer tube 83 extends in the upper side from the outer edge of the second coil support 82. The first peripheral wall 84, second peripheral wall 85, and third peripheral wall 86 are positioned inwardly in the radial direction than the outer tube 83 and extend in the upper side from the second coil support 82. The terminal holders 87A and 87B protrude outwardly in the radial direction from the outer tube 83.

The central axis J passes through the center of the second coil support 82, for example. The second coil support 82 includes a second supporter 82 a which supports the coil end 43 b. The second coil support 82 is disposed between the neutral point busbar 90 and the phase busbar 91 in the axis direction. Thus, the neutral point busbar 90 and the phase busbar 91 can be divided in up and down sides with the second coil support 82 interposed therebetween. Thus, the coil end 43 b can easily be disposed in a certain position.

The second supporter 82 a is a recess depressed from the inner edge of the second coil support 82 to the outer side thereof in the radial direction. The coil end 43 b passes inside the second supporter 82 a. The coil end 43 b is supported by the inner side surface of the second supporter 82 a from the both sides in the circumferential direction.

The center of the outer tube 83 is the central axis J. The first peripheral wall 84, second peripheral wall 85, and third peripheral wall 86 extend in the circumferential direction. The first peripheral wall 84 has an arc-like shape in a plan view. The second peripheral wall 85 and the third peripheral wall 86 are cylindrical having the same center with the outer tube 83. The second peripheral wall 85 is positioned inwardly in the radial direction than is the first peripheral wall 84. The third peripheral wall 86 is positioned inwardly in the radial direction than is the second peripheral wall 85.

The upper side end of the first peripheral wall 84 is at the same position with the upper side end of the outer tube 83 in the axis direction. The upper side end of the second peripheral wall 85 is positioned below the upper side end of the first peripheral wall 84 in the axis direction. The upper side end of the third peripheral wall 86 is positioned below the upper side end of the second peripheral wall 85.

The upper side buster holder 81 includes a first groove 81 a, second groove 81 b, and third groove 81 c depressed downwardly and extending in the circumferential direction. The first groove 81 a is positioned between the outer tube 83 and the first peripheral wall 84 in the radial direction. The second groove 81 b is positioned between the first peripheral wall 84 and the second peripheral wall 85 in the radial direction. The third groove 81 c is positioned between the second peripheral wall 85 and the third peripheral wall 86 in the radial direction.

The bottom of the first groove 81 a is positioned above the bottom of the second groove 81 b in the axis direction. The bottom of the second groove 81 b is positioned above the bottom of the third groove 81 c in the axis direction.

The terminal holders 87A and 87B are substantially rectangular in a plan view. The terminal holder 87A holds the terminal 92A. The terminal holder 87B holds the terminal 92B.

As shown in FIG. 2, the phase busbar 91 includes first phase busbars 93A and 93B, second phase busbars 94A and 94B, and third phase busbars 95A and 95B. That is, the motor 10 includes a plurality of phase busbars 91.

The first phase busbars 93A and 93B are held in the first grove 81 a. The second phase busbars 94A and 94B are held in the second groove 81 b. The third phase busbars 95A and 95B are held in the third groove 81 c.

The phase busbars 91 form a plurality of busbar groups of different connection systems. In the present embodiment, there are two busbar groups of a first busbar group including a first phase busbar 93A, second phase busbar 94A, and third phase busbar 95A, and a second busbar group including a first phase busbar 93B, second phase busbar 94B, and third phase busbar 95B.

Hereinafter, the connection system including the first busbar group may be referred to as connection system A, and the connection system including the second busbar group may be referred to as connection system B.

In the present application, a phrase such as structural elements of different connection systems indicates that different external power sources are electrically connected to the structural elements, and the power is supplied independently to each connection system. For example, if there are two connection systems A and B, there are two external power sources supplying the power to the motor 10, that is, the external power source electrically connected to the connection system A and the external power source electrically connected to the connection system B.

Two external power sources can independently supply the power to the motor 10. Even if one external power source supplying the power to one connection system fails to supply the power to the motor 10 for some reason, the other external power can supply the power to the other connection system. Thus, even if the power is not supplied to one connection system by a technical failure of the external power source or of a controller of the external power source, the motor 10 can be driven by supplying a current to the other connection system.

As shown in FIG. 3, the lower side busbar holder 71 includes a first coil support 72, lower side holder tube 73, inner side peripheral wall 74, and outer side peripheral wall 75.

The first coil support 72 is a substantially cylindrical plate around the central axis J. As shown in FIG. 4, the first coil support 72 is disposed above the coil 43. The first coil support 72 includes a first supporter 72 a supporting the coil end 43 b. Thus, the conductive wire 43 a of the coil 43 can be easily led while the insulation is maintained.

The first supporter 72 a is a recess depressed from the inner edge of the first coil support 72 to the outer side thereof in the radial direction. The coil end 43 b passes inside the first supporter 72 a. The coil end 43 b passing inside the first supporter 72 a is supported by the inner side surface of the first supporter 72 a from the both sides in the circumferential direction.

As shown in FIGS. 3 and 4, the lower side holder tube 73 is cylindrical around the central axis J. The lower side holder tube 73 extends from the first coil support 72 to the upper side. The inner side peripheral wall 74 and the outer side peripheral wall 75 are substantially annular extending in the circumferential direction. The inner side peripheral wall 74 is disposed inwardly than is the lower side holder tube 73 in the radial direction, and extends from the first coil support 72 to the upper side. The outer side peripheral wall 75 is disposed outwardly that is the lower side holder tube 73 in the radial direction, and extends from the first coil support 72 to the upper side.

The lower side busbar holder 71 includes a first lower side groove 71 a and a second lower side groove 71 b depressed downwardly and extending in the circumferential direction. The first lower side groove 71 a is positioned between the lower side holder tube 73 and the inner side peripheral wall 74 in the radial direction. The second lower side groove 71 b is positioned between the lower side holder tube 73 and the outer side peripheral wall 75 in the radial direction.

The neutral point busbar 90 includes a first busbar 90A and a second busbar 90B. As shown in FIG. 4, the first busbar 90A includes a first busbar body 90Aa extending in the circumferential direction and a first connection terminal 98A extending from the first busbar body 90Aa in the radial direction.

In a plan view, the first busbar body 90Aa is substantially annular. The first busbar body 90Aa is disposed in the first lower side groove 71 a. The first busbar body 90Aa is fit in the first lower side groove 71 a.

The first connection terminal 98A extends outwardly from the first busbar body 90Aa in the radial direction. In the present embodiment, the first busbar 90A includes nine first connection terminals 98A. The first connection terminals 98A are arranged at substantially regular intervals in the circumferential direction.

The first connection terminal 98A includes a first extension 96A and a first connector 97A. That is, the first busbar 90A includes the first extension 96A and the first connector 97A.

The first extension 96A extends from the first busbar body 90Aa in the radial direction. The first connector 97A is disposed in the end of the first extension 96A in the radial direction and is connected to the coil end 43 b.

As shown in FIG. 3, the shape of the first connector 97A is a letter U. Thus, when the lower side busbar assembly 70 is disposed above the stator 40, the coil end 43 b can be held by the first connector 97A. Thus, the first connector 97A and the coil end 43 b can easily be connected.

The first connector 97A is shaped as a letter U opening to the lower side. Thus, when the lower side busbar assembly 70 is disposed above the stator 40, the coil end 43 b can easily be grasped by the first connector 97A. Specifically, a lead line 45 g which will be described later can easily be grasped by the first connector 97A. Thus, the first connector 97A can easily be disposed to the coil end 43 b.

As shown in FIG. 4, the second busbar 90B includes a second busbar body 90Ba extending in the circumferential direction and a second connection terminal 98B extending from the second busbar body 90Ba in the radial direction.

In a plan view, the second busbar body 90Ba is substantially annular. The second busbar body 90Ba is disposed in the second lower side groove 71 b. The second busbar body 90Ba is fit in the second lower side groove 71 b.

The first busbar body 90Aa and the second busbar body 90Ba are disposed in the same position in the axis direction. The first busbar body 90Aa and the second busbar body 90Ba overlap with each other in the radial direction.

The second connection terminal 98B extends outwardly from the second busbar body 90Ba in the radial direction. In the present embodiment, the second busbar 90B includes nine second connection terminals 98B. The second connection terminals 98B are arranged at substantially regular intervals in the circumferential direction.

The second connection terminal 98B includes a second extension 96B and a second connector 97B. That is, the second busbar 90B includes the second extension 96B and the second connector 97B.

The second extension 96B extends from the second busbar body 90Ba in the radial direction. The second connector 97B is disposed in the end of the second extension 96B in the radial direction, and is connected to the coil end 43 b. The shape of the second connector 97B is the same with the shape of the first connector 97A.

The first connector 97A and the second connector 97B are disposed in the same position in the axis direction, for example. Thus, the connectors and the coil end 43 b can be connected at the same position in the axis direction. Thus, a process of connecting the first busbar 90A, second busbar 90B, and coil end 43 b can easily be performed.

As shown in FIG. 5, the insulator 44 includes an insulator tube 44 a, inner side plate 44 b, outer side plate 44 c, first base 46 b, second base 47 b, first protrusion 46 a, and second protrusion 47 a.

The insulator tube 44 a is annular and surrounds the teeth 42 in the both sides in the axis direction and the both sides in the circumferential direction. The insulator tube 44 a is, for example, a rectangular tube-like shape in the radial direction.

The inner side plate 44 b is a plate extending from the inner end of the insulator tube 44 a in the radial direction to the both sides in the axis direction and the both sides in the circumferential direction. The outer side plate 44 c is a plate extending from the outer end of the insulator tube 44 a in the radial direction to the both sides in the axis direction and the both sides in the circumferential direction.

As shown in FIGS. 6 to 8, the first base 46 b and the second base 47 b are each a substantially quadrangular prism. As shown in FIG. 6, the first base 46 b is disposed in the upper side end of the outer side plate 44 c in one side in the circumferential direction. The first base 46 b is disposed closer to the one side of the circumferential direction than are the teeth 42.

The second base 47 b is disposed in the upper side end of the outer side plate 44 c in the other side of the circumferential direction. The second base 47 b is disposed closer to the other side in the circumferential direction that are the teeth 42. As shown in FIG. 5, the first base 46 b and the second base 47 b are disposed above the core back 41. Note that the first base 46 b and the second base 47 b may be disposed to overlap with the teeth 42 in the axis direction.

As shown in FIG. 6, the first protrusion 46 a protrudes from the first base 46 b to the upper side. The first protrusion 46 a is a substantially quadrangular prism. The first protrusion 46 a is, in the upper end of the first base 46 b, disposed in the inner side end thereof in the radial direction and in the end thereof in the second base 47 b side in the circumferential direction.

The second protrusion 47 a protrudes from the second base 47 b to the upper side. The second protrusion 47 a and the first protrusion 46 a are disposed in the circumferential direction with a gap DP therebetween. The second protrusion 47 a is a substantially quadrangular prism. The second protrusion 47 a is, in the upper end of the second base 47 b, disposed in the inner side end thereof in the radial direction and in the end thereof in the first base 46 b side in the circumferential direction.

The first base 46 b includes a first inclined surface 46 c. The first inclined surface 46 c is disposed in the first protrusion 46 a in the side opposite to the second protraction 47 a in the circumferential direction. A distance between the first inclined surface 46 c and the central axis J increases toward the upper side in the radial direction.

The second base 47 b includes a second inclined surface 47 c. The second inclined surface 47 c is disposed in the second protrusion 47 a in the side opposite to the first protrusion 46 a in the circumferential direction. A distance between the second inclined surface 47 c and the central axis J increases toward the upper side in the radial direction.

Inclination φ2 of the second inclined surface 47 c with respect to the axis direction shown in FIG. 8 is less than inclination φ1 of the first inclined surface 46 c with respect to the axis direction shown in FIG. 7.

The coils 43 form a plurality of connection systems. Specifically, the coils 43 form two connection systems. That is, the first coil group including the coils 43 and the second coil group including the coils are formed wherein the connection systems of the first coil group and the second coil group are different.

The first busbar 90A and the first busbar group are electrically connected to the first coil group. The second busbar 90B and the second busbar group are electrically connected to the second coil group.

The first coil group and the first busbar 90A are included in the connection system A. The second coil group and the second busbar 90B are included in the connection system B.

Two coils 43 are disposed in each of the teeth 42 with the insulator 44 therebetween. The coils 43 include a first coil 45 a and a second coil 45 b. The first coil 45 a is disposed in the teeth 42 with the insulator 44 therebetween. The second coil 45 b is disposed in the teeth 42 with the first coil 45 a and the insulator 44 therebetween. That is, the second coil 45 b surrounds the first coil 45 a in the both sides in the axis direction and the both sides in the circumferential direction.

If the first coil 45 a and the second coil 45 b are formed in the teeth 42, the conductive wire is wound around the teeth 42 to form the first coil 45 a, and then, the conductive wire is wound over the first coil 45 a to form the second coil 45 b. That is, a winding end of the first coil 45 a and a winding start of the second coil 45 b cannot be provided at the same time. Thus, as compared to a case where two conductive wires are wound at the same time, the coil end 43 b of the first coil 45 a and the coil end 43 b of the second coil 45 b can easily be recognized by an operator or the like. Thus, confusion of the coil ends 43 b connected to the neutral point busbar 90 by an operator or the like can be suppressed. As a result, each first coil 45 a and each second coil 45 b can suitably be connected to the neutral point busbar 90, and the connection systems can be formed easily and more securely.

As shown in FIG. 6, the first coil end 45 c which is the coil end 43 b of the first coil 45 a contacts the first protrusion 46 a. The second coil end 45 d which is the coil end 43 b of the second coil 45 b contacts the second protrusion 47 a. That is, when the first coil 45 a and the second coil 45 b are formed, the conductive wire 43 a wound around the teeth 42 can be hooked onto the first protrusion 46 a and the second protrusion 47 a. Thus, the confusion of the first coil end 45 c and the second coil end 45 d by an operator or the like can further be suppressed.

The first coil end 45 c is hooked onto the first protrusion 46 a. The second coil end 45 d is hooked onto the second protrusion 47 a. At that time, the first coil end 45 c is guided along the first inclined surface 46 c. The second coil end 45 d is guided along the second inclined surface 47 c. Thus, the first coil end 45 c and the second coil end 45 d can easily be drawn by hooking them onto the first protrusion 46 a and the second protrusion 47 a.

The first coil end 45 c is a winding end line of the first coil 45 a. The second coil end 45 d is a winding start line of the second coil 45 b. The first coil end 45 c and the second coil end 45 d extend from the teeth 42 in the other side of the circumferential direction. That is, the first coil end 45 c and the second coil end 45 d extend from the same side of teeth 42 in the circumferential direction.

Thus, an angle formed by the first coil end 45 c extending from the teeth 42 to the first protrusion 46 a with respect to the axis direction, and an angle formed by the second coil end 45 d extending from the teeth 42 to the second protrusion 47 a with respect to the axis direction are different from each other.

Specifically, in FIG. 6, the first coil end 45 c is drawn from the other side of the teeth 42 in the circumferential direction, and is hooked onto the first protrusion 46 a in the one side in the circumferential direction. On the other hand, the second coil end 45 d is hooked onto the second protrusion 47 a in the other side in the circumferential direction, and extends in the other side of the teeth 42 in the circumferential direction. Thus, the inclination of the first coil end 45 c with respect to the axis direction is relatively greater than the inclination of the second coil end 45 d with respect to the axis direction.

As described above, the inclination φ2 of the second inclined surface 47 c is less than the inclination φ1 of the first inclined surface 46 c. Since the first coil end 45 c inclination of which with respect to the axis direction is relatively great can be disposed along the first inclined surface 46 c inclination of which is relatively great, the first coil end 45 c can easily be guided in the manufacturing process of the motor. Since the second coil end 45 d inclination of which with respect to the axis direction is relatively small can be disposed along the second inclined surface 47 c inclination of which is relatively small, the second coil end 45 d can easily be guided in the manufacturing process of the motor. Thus, the first coil end 45 c and the second coil end 45 d can easily be drawn by hooking them onto the first protrusion 46 a and the second protrusion 47 a. The first coil 45 a and the second coil 45 b wound around each of the teeth 42 included in either the first coil group or the second coil group having different connection systems. In each of the teeth 42, in the preferred embodiment, coil groups of the first coil 45 a and the second coil 45 b are different from each other.

As shown in FIG. 4, the first connector 97A, second connector 97B, first coil end 45 c, and second coil end 45 d are connected by, for example, welding.

The connection point of the first connector 97A and the second connector 97B and the connection point of the first coil end 45 c and the second coil end 45 d overlap with the gap DP in the radial direction. That is, the connection point between the first busbar 90A and second busbar 90B and the coil end 43 b overlaps with the gap DP in the radial direction. Thus, with the gap DP, a space to connect the coil end 43 b to the first busbar 90A and the second busbar 90B can be secured. Thus, the connection of the coil end 43 b, first busbar 90A, and second busbar 90B can easily be performed by, for example, welding.

Note that the first coil 45 a and the second coil 45 b may be formed of one continuous conductive wire 43 a. In that case, by connecting one of the first connectors 97A and 97B to a lead line 45 g (as shown in FIG. 6), two coil ends 43 b (that is, both of the first coil end 45 c and the second coil end 45 d) can be connected to the neutral point busbar 90. Thus, the number of attachment processes such as welding in the manufacturing process of the motor can be reduced half. Thus, a work load in the attachment process of the coil end 43 b and the neutral point busbar 90 can be reduced.

As shown in FIGS. 9A and 10A, a first coil forming step S1 is a step of forming the first coil 45 a by winding the conductive wire 43 a around the teeth 42. In the first coil forming step S1, the conductive wire 43 a is, for example, wound from the inner end of the teeth 42 in the radial direction with the insulator 44 therebetween.

As shown in FIGS. 9B and 10B, the first coil 45 a is formed in the first coil forming step S1. In the first coil forming step S1, a winding end position of the first coil 45 a is in the teeth 42 in the other side in the circumferential direction.

A lead line forming step S2 is a step of hooking the conductive wire 43 a which is the winding end of the first coil 45 a onto the insulator 44 to form a lead line 45 g. The winding end of the first coil 45 a which is the first coil end 45 c extending from the other side of the teeth 42 in the circumferential direction is drawn to the one side of the circumferential direction and hooked onto the first protrusion 46 a.

Then, the conductive wire 43 a is drawn to the second protrusion 47 a along the outer side of the first protrusion 46 a in the radial direction to be hooked onto the second protrusion 47 a. In other words, in the lead line forming step S2, the winding end of the first coil 45 a is hooked onto the first protrusion 46 a and then onto the second protrusion 47 a.

As described above, the lead line 45 g is formed as shown in FIG. 10B. That is, in the lead line forming step S2, the conductive wire 45 a is hooked onto the first protrusion 46 a and the second protrusion 47 a, and the lead line 45 g is formed in a position overlapping the gap DP in the radial direction.

A second coil forming step S3 is a step of winding the conductive wire 43 a which is the first coil 45 a and the lead line 45 g over the first coil 45 a to form the second coil 45 b. In the second coil forming step S3, a winding start position of the second coil 45 b is in the other side of the teeth 42 in the circumferential direction.

For example, if the drawing direction of the conductive wire 43 a is reversed in the formation of the lead line 45 g, the conductive wire 43 a hooked onto the second protrusion 47 a and the first protrusion 46 a in this order is drawn to diagonally downward from the one side to the other side in the circumferential direction. In that case, since the conductive wire 43 a is drawn diagonally from the upper side to the lower side, the wire 43 a tends to expand in the upper side. Thus, the conductive wire 43 a tends to be loose.

In consideration of this point, in the preferred embodiment, the winding end of the first coil 45 a is initially hooked onto the first protrusion 46 a in the lead line forming step S2. Thus, the winding end of the first coil 45 a drawn from the other side of the teeth 42 in the circumferential direction is drawn diagonally upward from the other side to the one side in the circumferential direction. Thus, the conductive wire 43 a diagonally drawn does not easily expand in the upper side, and the conductive wire 43 a can be prevented from becoming loose.

As shown in FIG. 9B, in the second coil forming step S3, the conductive wire 43 a is wound from the outer end of the teeth 42 in the radial direction with the insulator 44 and the first coil 45 a therebetween. In the second coil forming step S3, the second coil 45 b is formed (cf. FIGS. 9C and 10C).

As shown in FIGS. 9C and 10C, an arrangement step S4 is a step of arranging the first busbar 90A and the second busbar 90B in the lead line 45 g. The first busbar 90A and the second busbar 90B are brought in from the upper side of the stator 40, and the lead line 45 g can be held by the first connector 97A and the second connector 97B of letter U shape.

A cutting step S5 is a step of cutting the lead line 45 g between the position where the first busbar 90A is disposed and the position where the second busbar 90B is disposed. For example, the lead line 45 g is cut along a cut line Lc. Thus, as shown in FIG. 10D, the first coil end 45 c and the second coil end 45 d can be separated.

A connecting step S6 is a step of connecting the first busbar 90A and the second busbar 90B to the lead line 45 g cut as above. Specifically, the first connector 97A is connected to the first coil end 45 c, and the second connector 97B is connected to the second coil end 45 d. Thus, two neutral point busbars 90 of different connection system are connected to the first coil 45 a and the second coil 45 b, respectively. The first connector 97A and the second connector 97B are connected to the first coil end 45 c and the second coil end 45 d, respectively, by welding or the like.

Through the above steps, two coils 43 are connected to the neutral point busbars 90 of two different connection systems. Thus, two connection systems A and B can be formed while the confusion of coil ends 43 b to be connected to the neutral point busbars 90 by an operator or the like is suppressed.

A step of connecting one of the first busbar 90A and the second busbar 90B to the lead line 45 g may be added to the above steps. In that case, the step is performed as in the arrangement step S4 except that the neutral point busbar 90 connected to the lead line 45 g is one of the first busbar 90A and the second busbar 90B.

The invention of the present disclosure is not limited to the above-described preferred embodiment, and other structures can be adopted. In the following description, structural elements similar to those explained above will be referred to by the same reference numbers, and explanation considered redundant will be omitted.

The first coil end 45 c may be connected to one of the first busbar 90A and the second busbar 90B, and the second coil end 45 d may be connected to the other. That is, the first coil end 45 c may be connected to the second busbar 90B, and the second coil end 45 d may be connected to the first busbar 90A. Furthermore, the neutral point busbars 90 connected to the first coil end 45 c and the second coil end 45 d may be different in each of the teeth 42.

As long as the first coil 45 a and the second coil 45 b are wound around at least one of the teeth 42, there may be one or more coils 43 that are wound around some other teeth 42, for example.

The insulator 44 may be formed as in FIG. 11. As shown in FIG. 11, an insulator 144 includes a first wall 146 d and a second wall 147 d.

The first wall 146 d extends from the first base 46 b to the upper side. The first wall 146 d is, for example, a plate surface of which is orthogonal to the radial direction. The first wall 146 d is opposed to the first protrusion 46 a in the radial direction with a gap therebetween. The first protrusion 46 a and the first wall 146 d form a first holder 146 e.

The second wall 147 d extends from the second base 47 b to the upper side. The second wall 147 d is, for example, a plate surface of which is orthogonal to the radial direction. The second wall 147 d is opposed to the second protrusion 47 a in the radial direction with a gap therebetween. The second protrusion 47 a and the second wall 147 d form a second holder 147 e.

The coil ends 43 b are held by the first holder 146 e and the second holder 147 e. That is, the coil ends 43 b are held in a gap between the first wall 146 d and the first protrusion 46 a in the radial direction and a gap between the second wall 147 d and the second protrusion 47 a in the radial direction, respectively. Thus, when the lead line 45 g is formed by drawing the coil end 43 b, the coil end 43 b can easily be drawn without getting loose.

With the above structure, a strong force to pull the coil ends 43 b is not necessary to draw the coil ends 43 b without getting loose, and a force applied inwardly in the radial direction to the first protrusion 46 a and the second protrusion 47 a by the coil end 43 b can be reduced. Thus, a position shift of the insulator 144 caused by a strong force applied to the first protrusion 46 a and the second protrusion 47 a can be suppressed, and deformation of the first protrusion 46 a and the second protrusion 47 a can be suppressed.

The structures of the first base 46 b and the second base 47 b are not limited. For example, the first base 46 b and the second base 47 b may not protrude. For example, the outer side plate 44 c may function as a base.

The number of rotor core in the rotor 30 may be one. The motor 10 may be, for example, an outer rotor motor.

Features of the above-described preferred embodiments and the modifications thereof may be combined appropriately as long as no conflict arises.

While preferred embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims. 

What is claimed is:
 1. A manufacturing method of a motor which includes: a rotor including a shaft disposed along a central axis extending in a vertical direction; a stator opposed to the rotor in a radial direction with a gap therebetween; and a plurality of busbars electrically connected to the stator, wherein the stator includes: an annular core back extending in a circumferential direction; a plurality of teeth extending from the core back in the radial direction; a plurality of coils formed of a conductive wire wound around the teeth, the coils forming a plurality of connection systems; and an insulator, at least part of which is positioned between the teeth and the coils, and wherein a first coil group including the coils, and a second coil group including the coils, the first coil group and the second coil group forming different connection systems, and wherein the busbars include a first busbar electrically connected to the first coil group, and a second busbar electrically connected to the second coil group, the method comprising, in at least one of the teeth: a step S1 of forming a first coil winding the conductive wire around the teeth; a step S2 of hooking the conductive wire of a winding end of the first coil to form a lead line; and a step S3 of winding the conductive wire which is the same as the first coil and the lead wire over the first coil to form a second coil.
 2. The manufacturing method of the motor of claim 1, further comprising: a step S4 of disposing the first busbar and the second busbar on the lead line; and a step S5 of cutting the lead line between the part on which the first busbar is disposed and the part on which the second busbar is disposed.
 3. The manufacturing method of the motor of claim 2, further comprising a step S6 of connecting the first busbar and the second busbar to the lead line being cut.
 4. The manufacturing method of the motor of claim 1, wherein the insulator includes: a base disposed above the core back; a first protrusion protruding from the base toward an upper side; and a second protrusion protruding from the base toward the upper side, the first protrusion and the second protrusion disposed in the circumferential direction with a gap therebetween, and wherein, in the step S2, the conductive wire is hooked on the first protrusion and the second protrusion to form the lead line in a position overlapping the gap in the radial direction.
 5. The manufacturing method of the motor of claim 4, wherein the base includes, a first inclined surface disposed on one side of the first protrusion in the circumferential direction where a distance between the first inclined surface and the central axis in the radial direction increases toward the upper side, and a second inclined surface disposed on the other side of the second protrusion in the circumferential direction where a distance between the second inclined surface and the central axis in the radial direction increases toward the upper side, and wherein winding of the first coil ends in a position in the teeth in the other side in the circumferential direction in the step S1, and a winding end of the first coil is hooked on the first protrusion and then on the second protrusion in the step S2, and winding of the second coil starts in a position in the teeth in the other side in the circumferential direction in the step S3.
 6. The manufacturing method of the motor of claim 5, wherein inclination of the second inclined surface with respect to the axis direction is less than inclination of the first inclined surface with respect to the axis direction. 